Disposable waste containment garment

ABSTRACT

A disposable waste containment article includes a waste containment structure that has an absorbent composite which is positioned between the wearer and cover, and a pair of containment flaps operatively joined to the waste containment structure. The waste containment structure defines an open volume well formed between the absorbent core and the containment flaps for receiving directly and holding solid body exudates. Methods are provided for making the waste containment article.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a division of application Ser. No. 08/283,101, filed Jul. 29,1994, now U.S. Pat. No. 6,497,694, which is hereby incorporated byreference herein.

BACKGROUND OF THE INVENTION

This invention pertains to disposable waste containment articles, andmore particularly to articles providing containment and absorbency ofwaste matter while being useful as a swimsuit garment.

Currently, disposable waste containment articles find widespread use inthe areas of adult care, infant care, and child care, and have generallyreplaced reusable cloth articles. Disposable diapers, for example, havemet a particular need and have become very popular. Disposable trainingpants have also met a particular need and have become popular. However,once a child desires to travel to a swimming-pool or beach, the childrequires a waste containment garment for possible “accidents” duringsuch travel.

Although it is desired by the parent that the child not have an accidentwhile wearing a swimsuit garment, accidents will occur and, during thosetimes containment and limited absorbency is required. In addition,through the use of increased amounts of superabsorbents in disposablediapers and training pants, greatly enhanced absorbent capacities andleakage performance have been achieved under normal usage conditions.However, when infants and toddlers swim, the superabsorbent material(SAM) causes the diaper/pant to absorb water to its maximum capacity,therefore swelling to proportions typically not seen in normal use. Thediaper/pant sags, becomes uncomfortable and heavy and does not fit underchildren's swimsuits. In some cases, the diaper/pant actually bursts,leaving globules of superabsorbent to litter the poolside or beach, orbecome clogged in pool filters. This also releases fecal mattercontained in the diaper/pant. It is not uncommon for public pools to bansuperabsorbent-containing diapers. However, the urine containment needsof children before they enter the water and the BM containment requiredin the water suggest that a containment garment is needed.

SUMMARY OF THE INVENTION

Thus, there is a need to provide an improved child's swimming apparelthat minimizes the leakage of urine and fecal matter during travel toswimming while maintaining fecal containment during swimming. Inresponse to this need, a new waste containment garment and method ofmaking a waste containment garment have been discovered that contains adiaper-like waste containment structure to absorb urine when dry andcontain BM when dry or wet. A waste containment garment according to theinvention includes a waste containment structure having a longitudinalaxis and opposite longitudinally spaced ends. The waste containmentstructure comprises an absorbent core, a backsheet and containmentflaps. The structure contains little or no SAM so it does not swell upwhen wet. The absorbent is a mix of pulp and polymer coformed to give itdurability when wet. The polymer-based fabric of the outer garment islightweight, allowing for quick drying out of the water.

In another embodiment of the present invention there is provided adisposable waste containment article having a waste containmentstructure including a backsheet and an absorbent core, the backsheethaving a pair of leg elastics along the longitudinal edges of thebacksheet. A pair of containment flaps are joined to the wastecontainment structure outside the leg elastics.

In still another embodiment of the present invention there is provided amethod of making a disposable waste containment article comprising thesteps of providing a waste containment structure, supplying a pair ofcontainment flaps having distal edges, placing the containment flapswith the waste containment structure and joining the containment flapsto the waste containment structure.

Numerous features and advantages of the present invention will appearfrom the following description. In the description, reference is made tothe accompanying drawings which illustrate preferred embodiments of theinvention. Such embodiments do not represent the full scope of theinvention. Reference should therefore be made to the claims herein forinterpreting the full scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features of the present invention and themanner of attaining them will become more apparent, and the inventionitself will be better understood by reference to the followingdescription of the invention, taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a front view of a pant typifying an embodiment of the presentinvention for a girl's swimsuit;

FIG. 2 is a front view of a pant typifying an embodiment of the presentinvention for a girl's swimsuit;

FIG. 3 is a cross-sectional view of FIG. 1 taken along line 3—3 andviewed in the direction of the arrows.

FIG. 4 is a perspective view of a diaper embodying the present inventionand showing the opening/closing arrangement.

FIG. 5 is a front view of a pant for a boy's swimsuit showing the crotcharea of the cover.

FIG. 6 is a perspective view diaper for a boy's swimsuit view showingembodying the present invention and showing the opening/closingarrangement.

FIG. 7 is a perspective view of a pant for a boy's swimsuit showing theinvention in an opened out view.

DEFINITIONS

Within the context of this specification, each term or phrase below willinclude the following meaning or meanings:

-   -   (a) “Bonded” refers to the joining, adhering, connecting,        attaching, or the like, of two elements. Two elements will be        considered to be bonded together when they are bonded directly        to one another or indirectly to one another, such as when each        is directly bonded to intermediate elements.    -   (b) “Disposable” includes being disposed of after use, and not        intended to be washed and reused.    -   (c) “Disposed”, “disposed on”, “disposed with”, “disposed at”,        “disposed near”, and variations thereof are intended to mean        that one element can be integral or unitary with another        element, or that one element can be a separate structure joined        to or connected to or placed with or placed near another        element.    -   (d) “Elasticity” and “elastic” include that property of a        material by virtue of which it tends to substantially recover to        its original size and shape after removal of a force causing        deformation of the material.    -   (e) “Elastically connected” and “elastically connecting” refer        to two elements being separated by and bonded to an elastic        member, where the relative position of the two elements may        change due to extension of the elastic member.    -   (f) “Elongation” includes the ratio of the extension of a        material to the length of a material prior to the extension.        Elongation is expressed in percent.    -   (g) “Extension”, “extend”, and “extended” include the change in        length of a material due to stretching. Extension is expressed        in units of length.    -   (h) “Force” includes a physical influence exerted by one body on        another which produces acceleration of bodies that are free to        move and deformation of bodies that are not free to move. Force        is expressed in grams-force.    -   (i) “Foreshortened” and “foreshortening” include to shorten        beforehand, that is, before a subsequent step.    -   (j) “Front” and “back” are used to designate relationships        relative to the garment itself, rather than to suggest any        position the garment assumes when it is positioned on a wearer.    -   (k) “Member” when used in the singular can have the dual meaning        of a single element or a plurality of elements.    -   (l) “Operatively joined” with reference to the attachment of an        elastic member to another element means that the elastic member        when attached to or connected to or treated with heat with the        element gives that element elastic properties. With reference to        the attachment of a non-elastic member to another element, it        means that the member and element can be attached in any        suitable manner that permits or allows them to perform the        intended or described function of the joinder. The joining,        attaching, connecting or the like can be either directly, such        as joining either member directly to an element, or can be        indirectly by means of another member or element disposed        between the first member and the first element.    -   (m) “Pervious” means that a layer of material is able to pass or        transport a detectable amount of liquid under conditions        normally encountered in a diaper/pant during use.    -   (n) “Porous” means that a layer of material is able to pass or        transport a measurable amount of liquid under conditions        normally encountered in a diaper/pant during use.    -   (o) “Rupture” includes the breaking or tearing apart of a        material; in tensile testing, rupture refers to the total        separation of a material into two parts either all at once or in        stages, or the development of a hole in some materials.    -   (p) “Stretch bonded” refers to an elastomeric strand being        bonded to another member while the elastomeric strand is        elongated at least about 25 percent of its relaxed length.        Desirably, the term “stretch bonded” refers to the situation        wherein the elastomeric strand is elongated at least about 100        percent, more desirably at least about 300 percent, of its        relaxed length when it is bonded to the other member.    -   (q) “Stretch bonded laminate” (“SBL”) refers to a composite        material having at least two layers in which one layer is a        gatherable layer and the other layer is a stretchable, that is,        elastic, layer. The layers are joined together when the        stretchable layer is in a stretched condition so that upon        relaxing the layers, the gatherable layer is gathered.    -   (r) “Tension” includes a uniaxial force tending to cause the        extension of a body or the balancing force within that body        resisting the extension.    -   (s) “Two-dimensional” refers to a garment, such as a diaper,        that can be opened and laid in a flat condition without        destructively tearing any structure. This type of garment does        not have continuous leg and waist openings when opened and laid        flat, and requires a fastening device, such as adhesive tapes,        to attach the garment about the wearer.    -   (t) “Three-dimensional” refers to a finished garment similar to        shorts or pants in that they have continuous leg and waist        openings that are bounded by the material of which the garment        is made. This type of garment can be opened and laid flat only        by destructively tearing it. This type of garment may or may not        have manually tearable seams.    -   (u) “Ultimate elongation” includes the elongation at the point        of rupture.        These definitions are not intended to be limiting and these        terms may be defined with additional language in the remaining        portion of the specification.

Description of a Preferred Embodiment

A pant 10 using this invention, shown in FIGS. 1 and 2, includes a wastecontainment structure 12, which can be made or constructed in a varietyof ways, one of which is described in U.S. patent application Ser. No.043,132 filed on Mar. 25, 1993, a corresponding application of which waspublished as EP 0,547,497, which U.S. Application is incorporated byreference herein. Other pant designs are described in U.S. Pat. Nos.4,938,757, 4,747,846, and 4,940,464; the contents of these three patentsare incorporated by reference herein.

The pant 10 is illustrated partially opened out in FIG. 7. The structure12 includes front and back longitudinally spaced waist regions 20 and22, which terminate in longitudinal ends of the pant 10. A crotch area24 is located between the front and back waist regions 20 and 22. Thewaist regions 20 and 22 together with crotch area 24 form a wastecontainment section 42 (FIG. 2). Left and right side panels 26 and 28extend between the front and back waist regions 20 and 22.

As illustrated most clearly in FIGS. 2 and 7, the edges 27 and 29 ofside panels 26 and 28 may be bonded together in the finished pant toform manually tearable, non-refastenable seams 44 and 46. The seams 44and 46 may be formed by any suitable means such as ultrasonic sealing,adhesive bonding, heat sealing, or the like. One suitable method offorming such seams is disclosed in U.S. Pat. No. 4,938,753 issued Jul.3, 1990, to Van Gompel et al., which is incorporated herein byreference. The waste containment structure 12 thus defines a waistopening 34 and a pair of leg openings 30 and 32 (FIGS. 1 and 2).

In FIG. 2, waste containment structure 12 generally comprises wastecontainment section 42 and side panels 26 and 28. Side panels 26 and 28,which may or may not have elastic characteristics, are ultrasonicallybonded and are formed such that the materials of construction provide amanually tearable, nonrefastenable region near the seams 44 and 46. Theside panels 26 and 28 can be rendered elastic by incorporating a layerof elastic material or an SBL. Alternatively, the structure 12 can berendered elastic by incorporating strands of elastics about the body ofthe structure or by incorporating a layer of elastic material or an SBLthroughout the exterior of the structure 12.

Waste containment section 42 includes the containment flaps 64 and 66,backsheet 58, liner 56, absorbent core 60 and side panels 26 and 28.Containment flaps 64 and 66 have respective distal ends 82 and 84. FIG.3 shows the generally upright position containment flaps 64 and 66assume when pant 10 is being pulled on and worn. It is understood that,although waste containment structure 12 is illustrated here as beingflat for ease of understanding, waste containment structure 12, in fact,assumes a bowed- or bucket-like shape in the crotch area 24 asillustrated in FIGS. 2 and 3.

One specific method of attachment is described in U.S. patentapplication Ser. No. 054,508 filed Apr. 26, 1993, now U.S. Pat. No.5,895,382, issued Apr. 20, 1999, and assigned to the assignee of thisapplication; the contents of this patent application is incorporated byreference herein. The proximal edges of flaps 64 and 66 may be attachedinboard or outboard of the leg elastics 36 (FIG. 3) and 38, however, itis desirable that they be placed outboard.

With reference to FIGS. 3 and 7, the waste containment structure 12 asillustrated includes a backsheet 58, a substantially liquid permeablebodyside liner 56, and an absorbent core 60 sandwiched between thebacksheet and the liner. The backsheet 58 and bodyside liner 56 aredesirably longer and wider than the absorbent core 60, so that theperipheries of the backsheet and liner form margins which may be sealedtogether using ultrasonic bonds, thermal bonds, adhesives, or othersuitable means. The absorbent core 60 may be attached to the backsheet58 and/or the bodyside liner 56 using ultrasonic bonds, adhesives, orother suitable means. The waste containment structure 12 may alsoinclude additional components to assist in the acquisition, distributionand storage of waste material. For example, the waste containmentstructure 12 may include a transport layer, such as described in U.S.Pat. No. 4,798,603 issued Jan. 17, 1989, to Meyer et al., or a surgemanagement layer, such as described in European Patent Application EP 0539 703 A1, published May 5, 1993, which patent and application areincorporated herein by reference.

Leg elastics 36 and 38 can be stretch bonded to the cover material alongthe longitudinal edges of the structure 12. The waist elastic 116 and117 elasticizes the waist regions 20 and 22 of the waste containmentstructure 12. Thereafter, each side panel 26 and 28 can be bondedtogether by seams 44 and 46 (FIG. 2) so that the waste containmentstructure 12 defines the waist opening 34 and the pair of leg openings30 and 32. The two leg elastics are placed desirably from about 10 toabout 16 cm apart for a 17 to 30 pound child.

In FIG. 7, pant 10 is in a partial opened state showing edges 27 and 29which are joined to form seams not shown, thus forming the finishedtraining pant 10. In FIGS. 5 and 7, to construct the cover 14 of thepreferred embodiment for training pant 10, the front panel section 94may be joined with the back panel 96 along seams 122 and 124 and in thecase of a boxer short at crotch area seam 126 and to waste containmentstructure 12 at front and back waist regions 20 and 22 near the waistopening 34. The term “finished pant” means a three-dimensional trainingpant that can be used for its intended purpose. The waste containmentstructure 12 may optionally be T-shaped, I-shaped, hourglass-shaped, orirregularly-shaped.

In FIG. 3, the waste containment structure 12 also desirably includesleg elastics 36 and 38 operatively joined to the backsheet 58, thebodyside liner 56, or both. The leg elastics 36 and 38 are positionedalong the edges of side panels 26 and 28 and the longitudinal edges 112and 113 of the waste containment structure 12 in the crotch area 24. Theleg elastics 36 and 38 may assist in holding the waste containmentstructure 12 against the body of the wearer or forming seals or gasketsabout the legs of the wearer.

The waste containment structure 12 can be constructed by supplyingbodyside liner and backsheet materials and sandwiching an individualabsorbent core 60 between the backsheet 58 and bodyside liner 56. Theside peripheries of the backsheet 58 and bodyside liner 56 outward ofthe absorbent core 60 can be joined with side panel material. Individualwaste containment structure 12 can then be cut from the continuoussupply of backsheet and bodyside liner materials.

Referring primarily to FIGS. 4 and 6, a disposable, two-dimensionalgarment is shown as diaper 210. The diaper 210 includes wastecontainment structure 212, front waist region 220 including oppositelydisposed front ear sections 244 and 246, back waist region 222 includingfasteners 252 and 254 on respective oppositely disposed back earsections 248 and 250, and crotch area 224 between front waist region 220and back waist region 222. Diaper 210 may further comprise a cover 214.

The waste containment structure 212 further comprises a backsheet 258, aliner 256, and an absorbent core (not shown) disposed between backsheet258 and liner 256. Waste containment structure 12 includes containmentflaps 274 and 276 having elastic members (not shown) attached thereto.

A more detailed description of the structure of a typical diaper 210,its process of manufacture, and method of use are contained in U.S. Pat.No. 4,704,116, which is assigned to the assignee of the presentinvention, the contents of which are incorporated by reference herein.

For application of the diaper to an infant and in reference to FIG. 4,the infant may be placed upon back waist region 222 of diaper 210 inpreparation of fitting and attaching the diaper 210. The legs of theinfant are spread apart so that front waist region 220 can be easilyfolded upwardly over the front of infant in a manner that snugly fitscrotch area 224 against the infant. Thereafter, fasteners 252 and 254are attached to the outermost surface of respective front ear sections244 and 246.

The absorbent core 60 is desirably relatively thin to provide an overallthinness dimension to the pant 10. The absorbent core 60 desirably has abulk thickness which is not more than about 1.25 cm, and particularlynot more than about 0.7 cm when dry. The thickness is measured accordingto the thickness test shown in the Example. The bulk thickness isdetermined under a restraining pressure of 0.2 pounds per square inch(1.38 kPa). Further, the absorbent core 60 suitably has an absorbentcapacity of at least about 60 grams, and desirably at least about 100grams, of synthetic urine. The capacity is measured according to thesaturation capacity that is shown in the Example.

The coform material may comprise an airlaid blend of cellulosic woodfibers and meltblown polyolefin fibers, such as polyethylene orpolypropylene fibers, or may comprise an air-formed batt of cellulosicfibers (i.e., wood pulp fluff). Optionally, the absorbent core 60 may betreated with a surfactant to aid in liquid acquisition when in a dryenvironment. In particular embodiments of the invention, the absorbentcore 60 has a bulk thickness of not more than about 1.25 cm when dry.The hydrophilic fibers and polymer strands may be provided in afiber-to-polymer ratio which is less than 80:20, for example betweenabout 30:70 and about 80:20 and, desirably between about 60:40 and about70:30.

The absorbent core 60 can comprise a coform material composed of amixture of cellulosic fibers and synthetic polymer fibers. For example,the coform material may comprise an airlaid blend of cellulosic woodfibers and meltblown polyolefin fibers, such as polyethylene orpolypropylene fibers. Absorbent core 60 can comprise only coform, or acombination of superabsorbent materials and coform, with other absorbentor non-absorbent materials. Optionally, the core may be treated with asurfactant to aid in liquid acquisition when in a dry environment. Inparticular embodiments of the invention, the absorbent core has a bulkthickness of not more than 0.9 cm when wet. Preferably, the wet bulkthickness is less than 0.8 cm. The core should be flexible across thediaper so as to encourage formation of a bucket in the crotch region ofthe structure 12.

For absorbent core 60, compounds to increase the core absorbency, areincluded in an effective amount and may consist of organic or inorganichigh-absorbency materials. For example, the absorbent core 60 caninclude 0-5 weight percent high-absorbency material, preferably lessthan 1%. Suitable inorganic high-absorbency materials include, forexample, absorbent clays and silica gels.

Organic high-absorbency materials can include natural materials, such aspectin, guar gum and peat moss, as well as synthetic materials, such assynthetic hydrogel polymers. Such hydrogel polymers may include, forexample, carboxymethylcellulose, alkali metal salts of polyacrylicacids, polyacrylamides, polyvinyl alcohol, ethylene maleic anhydridecopolymers, polyvinyl ethers, hydroxypropyl cellulose, polyvinylmorpholinone, polymers and copolymers of vinyl sulfonic acid,polyacrylates, polyacrylamides, polyvinyl pyrridine or the like. Othersuitable polymers can include hydrolyzed acrylonitrile grafted starch,acrylic acid grafted starch, and isobutylene maleic anhydridecopolymers, and mixtures thereof.

The hydrogel polymers are preferably sufficiently cross-linked to renderthe materials substantially water-insoluble. Cross-linking may, forexample, be by irradiation or by covalent, ionic, van der Waals orhydrogen bonding. Suitable materials are available from variouscommercial vendors, such as Dow Chemical Company, Hoechst-CelaneseCorporation and Allied-Colloid. Typically, the high-absorbency materialis capable of absorbing at least about 15 times its weight in water, andpreferably is capable of absorbing more than about 25 times its weightin water.

The high-absorbency material can be distributed or otherwiseincorporated into the absorbent core 60 employing various techniques.For example, the high-absorbency material can be substantially uniformlydistributed among the fibers comprising the absorbent core. Thematerials can also be nonuniformly distributed within the absorbent corefibers to form a generally continuous gradient with either an increasingor decreasing concentration of high-absorbency material, as determinedby observing the concentration moving inward from the backsheet 58.Alternatively, the high-absorbency material can comprise a discretelayer separate from the fibrous material of the absorbent core 60, orcan comprise a discrete layer integral with the absorbent core.

The absorbent core 60 may also include a wrap layer to help maintain theintegrity of the fibrous core. This wrap may comprise a hydrophilicspunbond, meltblown or bonded-carded web material composed of syntheticpolymer filaments, such as polypropylene, polyethylene, polyesters orthe like or natural polymer filaments such as rayon or cotton.

The bodyside liner 56 may be any soft, flexible, porous sheet whichpasses fluids therethrough. Again, the liner must permit submersion infresh water, salt water, or treated water and still retain itsintegrity. The bodyside liner 56 may comprise, for example, a nonwovenweb or sheet of a spunbonded, meltblown or bonded-carded web composed ofsynthetic polymer filaments, such as polypropylene, polyethylene,polyesters or the like, or a web of natural polymer filaments such asrayon or cotton. The bodyside liner 56 has a pore size that readilyallows the passage therethrough of liquids, such as urine and other bodyexudates. The liner 56 may be selectively embossed or perforated withdiscrete slits or holes extending therethrough. Optionally, the web orsheet may be treated with a surfactant to aid in liquid transfer. Onesuitable bodyside liner material is a wettable spunbonded polypropyleneweb produced by the methods and apparatus described in U.S. Pat. No.4,340,563 issued Jul. 20, 1982, and U.S. Pat. No. 4,405,297 issued Sep.23, 1983, to Appel et al., which are incorporated herein by reference.Bodyside liner 56 is liquid permeable and is a spunbonded polypropylenenonwoven web having a basis weight of about 0.75 oz/yd² (25.4 gsm).Suitable adhesives for adhering the laminate layers can be obtained fromFindley Adhesives, Inc. of Wauwatosa, Wis.

The backsheet 58 may comprise a thin, liquid impermeable web or sheet ofplastic film such as polyethylene, polypropylene, polyvinyl chloride orsimilar material. Alternately, the backsheet 58 may comprise a nonwoven,fibrous web which has been suitably constructed and arranged to have lowliquid perviousness. Still alternately, the backsheet may comprise alayered or laminated material, such as a thermally bonded plastic filmand nonwoven web composite. Since the garment is typically intended foractive wear, an exposed backsheet or portions thereof, can be made ofmaterials or of a basis weight which is abrasion resistent.

The backsheet 58 may be constructed of a single spunbonded polypropylenenonwoven web having a basis weight of about 0.5 oz/yd² (17 gsm) to about2.0 oz/yd² (68 gsm). In the case of a boy's boxer short type article,the cover preferably comprises a material having a basis weight of fromabout 0.5 oz/yd² (23.8 gsm) to about 2.0 oz/yd² (68 gsm). In the case ofa girl's skirt type article, the cover preferably comprises a materialhaving a basis weight of from about 0.5 oz/yd² (23.8 gsm) to about 2.0oz/yd² (68 gsm), preferably 1.0 oz./yd² to 2.0 oz./yd² at least in thecrotch and buttocks regions of the backsheet. Lesser basis weights maybe used in other regions of the article.

The elastic side panel material desirably has stretch characteristics ina first direction such that it is capable of from about 10 to about 500percent elongation and upon release of tension will recover at least 55percent of its elongation. It is generally preferred that the side panelmaterial in the first direction be capable of between about 50 and about300 percent elongation, particularly at least 125 percent elongation andrecovery upon release of tension of at least 80 percent of itselongation.

As described previously, the side panels 26 and 28 may be formed of amaterial capable of stretching in one direction or capable of stretchingin at least two substantially perpendicular directions. One suitableone-directional stretch material is disclosed in U.S. Pat. No. 4,720,415issued Jan. 19, 1988, to Vander Wielen et al., which is incorporatedherein by reference. The one-directional stretch material may comprise acomposite material including at least one gatherable web bonded to atleast one elongated elastic web. The elastic web may be an elastic filmor nonwoven fibrous elastic webs such as meltblown elastomeric fibrouswebs. In one embodiment, the side panels comprise a stretch bondedlaminate formed of a prestretched elastic meltblown inner layersandwiched between and attached to a pair of spunbond polypropylenenonwoven webs having a basis weight of about 0.4 oz/yd² (13.6 gsm).Suitable elastic materials can be purchased from the Shell ChemicalCompany of Houston, Tex. under the trade name Kraton. Other suitableone-directional stretch materials are disclosed in U.S. Pat. No.4,606,964 issued Aug. 19, 1986, to Wideman and U.S. Pat. No. 4,657,802issued Apr. 14, 1987, to Morman.

Suitable two-directional stretch materials for the side panels 26 and 28are disclosed in U.S. Pat. No. 5,114,781 issued May 19, 1992, and U.S.Pat. No. 5,116,662 issued May 26, 1992, to Morman, which areincorporated herein by reference.

A two-directional stretch material may comprise a composite materialincluding a neckable material and an elastic sheet, which may be formedby meltblowing or extrusion. Neckable materials are those which may beconstricted in at least one dimension by applying a tensioning force ina direction perpendicular to the desired direction of neck-down, and mayinclude a spunbonded, meltblown or bonded carded web. The tensioned,necked neckable material may be joined to the elongated elastic sheet atspaced locations arranged in a nonlinear configuration. Anothertwo-directional stretch composite material may comprise one or morelayers of reversibly necked material joined to one or more layers ofelastic sheet at spaced locations. Reversibly necked materials are thosethat have been treated, such as with heat, while necked to impart memoryto the material so that, when a force is applied to extend the materialto its pre-necked dimensions, the treated, necked portions willgenerally recover to their necked dimensions upon termination of theforce.

In reference to FIG. 3, each containment flap 64 and 66 has a flapheight, HF, measured between the respective distal edges 82 and 84 andrespective proximal edges 72 and 74 (see FIG. 3). Flap height HF has arange between about 2 cm to about 8 cm, and a desired range of about 3cm to about 5 cm.

Flap height HF and the elastic characteristics of flap elastics 128 and130 determine the anatomical location of distal edges 82 and 84 and well86 at the crotch of the wearer. For example, distal edges 82 and 84 canshift too close together such that flaps 64 and 66 form a tent overabsorbent core 60, thereby preventing absorption of urine or other wastematter.

The containment flap material may comprise a thin, liquid impermeableweb or sheet of plastic film such as polyethylene, polypropylene,polyvinyl chloride or similar material. Alternately, the flap materialmay comprise a nonwoven, fibrous web which has been suitably constructedand arranged to have low liquid perviousness. Still alternately, theflaps may comprise a layered or laminated material, such as a thermallybonded plastic film and nonwoven web composite. The flap material, filmsor nonwoven, may be apertured to increase the porous nature of the flap.Desirably, such apertures have a density of 10/ cm² and have a diameterof about 0.125 cm.

It is desirable to provide consistent containment flap positioningwithin the crotch of the wearer as shown in FIGS. 3 and 4. Additionally,because of the relatively large dimension of flap height HF, whenabsorbent core 60 becomes heavier due to the absorption of waste matterand begins to sag downwardly, containment flaps 64 and 66 will extend tomaintain their seal, thereby containing liquid and other waste matter inopen volume well 86 for receiving directly and holding solid bodyexudates until absorbent core 60 has time to absorb the liquid wastematter in a dry environment, and the liquid has had time to strainthrough the flap to leave the solid waste matter in the volume well 86in a wet environment or upon exit from a wet environment. Preferably,the liquid initially trapped when a wearer first leaves a swimming poolwill drain from the waste containment structure rather quickly,desirably in less than 30 seconds.

In reference to FIG. 3, flap elastics 128 and 130, which may be a singleribbon of elastic material or a plurality of strands of elasticmaterial, have a predetermined elongation and tension in order to assistin properly positioning containment flaps 64 and 66. In order forcontainment flaps 64 and 66 to assume a desired upright orientation, asshown in FIG. 3, to contact and seal against wearer's thighs, each flapelastic 128 and 130 desirably has a minimum of about 90 percentelongation when incorporated into flap 64 and 66 of a finished pant 10.A desired range of elongation is between about 90 percent to about 150percent stretch. A desired tension range for each flap elastic 128 and130 is between about 90 grams-force to about 200 grams-force at 90percent of ultimate elongation.

Flap elastics 128 and 130 in containment flaps 64 and 66 are strands ofLycra T151 940 decitex elastic which can be obtained from E. I. du Pontde Nemours Co., Wilmington, Del. The flap material is a spunbondpolypropylene nonwoven web having a basis weight of about 0.7 oz/yd²(23.7 gsm). It is desired that the nonwoven layer be at least liquidpermeable and preferably liquid porous.

As absorbent core 60 becomes heavier due to its absorbing waste,absorbent core 60 will tend to sag or move downwardly, away from thecrotch. However, containment flaps 64 and 66 will be able to extend inheight, as shown in FIG. 3, to maintain the seal against the crotch.Although the absorbent core 60 will have a tendency to sag, it will alsoexpand, thereby filling a portion of well 86. In this invention, theabsorbency is desirably limited to provide a wet diaper BM containmentof at least about 250 cm³ in the wet state, desirably 300 cm³ and moredesirably 400 cm³. For purpose of this invention wet state is treatedgarment with water in an amount equal to its saturation capacity asdescribed in the Example. The garment for test purposes should have awidth between the proximal edges of the containment flaps not greaterthan 14 cm and a length of the overall garment of not greater than 43cm.

The leg elastics 36 and 38 may be formed of a stretch bonded laminate.In particular, the stretch bonded laminate may comprise at least onenonwoven gatherable layer and an elastic layer. Alternately, the legelastics 36 and 38 may be formed of a dry-spun coalesced multifilamentelastomeric thread sold under the tradename LYCRA and available fromI.E. Du Pont de Nemours and Company. Still alternately, the elastics maybe formed of other typical elastics utilized in the diaper-making art,such as a thin ribbon of elastic material as disclosed in U.S. Pat. No.4,940,464 issued Jul. 10, 1990, to Van Gompel et al., which isincorporated herein by reference. Elasticity could also be imparted tothe longitudinal side sections by extruding a hot melt elastomericadhesive between the backsheet 58 and the bodyside liner 56. Othersuitable elastic gathering means are disclosed in U.S. Pat. No.4,938,754 to Mesek and U.S. Pat. No. 4,388,075 to Mesek et al.

The foregoing detailed description has been for the purpose ofillustration. Thus, a number of modifications and changes may be madewithout departing from the spirit and scope of the present invention.For instance, alternative or optional features described as part of oneembodiment can be used to yield another embodiment. Additionally, onlyone rather than both ends of the waste containment structure can beelastically connected to the cover. Therefore, the invention should notbe limited by the specific embodiments described, but only by theclaims. The materials of which pant 10 are made, including containmentflaps 64 and 66 can be any materials specifically desired by the user ormanufacturer. Numerous examples of materials used in constructing pant10 and diaper 210 are described in the aforementioned U.S. patents andpatent applications incorporated by reference herein.

EXAMPLE Bulk Thickness Wet and Dry and the Saturated Capacity

Each product was opened, the leg elastics snipped and laid flat. Theproduct was sectioned into three parts, front, center and back. Using anAMES thickness gauge under 0.2 psi pressure, the thickness was measuredfor each section, the front, center and back, and recorded as shown inTable I below. The weight of each section while dry was measured usingMettler scale and recorded. The sections were then submerged in a bathof tap water for ½ hour. The sections were removed from the bath andplaced on open screen for 5 minutes to allow excess water to drip out ofeach section. Each section was then weighed and the saturated weightresults were recorded as shown in Table II below. Each section was thenmeasured under the AMES thickness gauge using 0.2 psi and the saturatedthickness was recorded as shown in Table I below.

TABLE I THICKNESS, mm Standard Back Middle Front Average Deviation A Dry4.08 8.14 5.36 5.86 2.08 Wet 4.72 8.16 5.60 6.16 1.79 B Dry 3.58 6.365.13 5.02 1.39 Wet 28.70 33.68 33.80 32.06 2.91 C Dry 5.26 8.68 5.606.51 1.88 Wet 33.90 34.72 34.15 34.26 .42 D Dry 9.83 11.52 13.43 11.591.80 Wet 31.70 34.79 34.77 33.75 1.78 E Dry 9.03 10.32 8.90 9.42 .79 Wet11.56 12.20 13.08 12.28 .76 F Dry 9.45 10.20 8.42 9.36 .89 Wet 25.8620.85 17.31 21.34 4.30 G Dry 6.24 8.36 6.37 6.99 1.19 Wet 25.80 24.7032.10 27.53 3.99 H Dry 3.35 6.38 4.83 4.85 1.52 Wet 4.74 9.89 8.36 7.662.64 A Product of this invention B HUGGIES ® Supertrim Step 3 diapermanufactured by Kimberly-Clark Corporation, Neenah, WI. C PAMPERS ®Ultra Dry Thin Crawler/Walker diaper manufactured by Procter & GambleCompany D HUGGIES ® PULL-UPS ® training pant manufactured byKimberly-Clark Corporation E DRYPERS ® diaper manufactured by DrypersCorporation F FITTI ® diaper manufactured by Associated HygienicsCorporation G WONDER DRYS ® diaper manufactured by Paragon Trade BrandsCorporation

TABLE II Saturation Capacity, g A 160.66 B 1274.11 C 1403.75 D 976.01 E553.59 F 913.84 G 1175.55 H 277.83

To determine the wet solid waste capacity:

Each product was treated with tap water in an amount equal to itsrespective saturation capacity. The product was allowed to equilibratefor 2 minutes. The wet product was then placed in a normal position on astanding baby model. A flexible PVC plastic tube having a diameter of{fraction (3/16)} inch was positioned between the product and the babymodel at a location which approximated that of the anus of a baby.Synthetic BM was prepared using the following ingredients: 300 grams ofBetty Crocker Potato Buds (manufactured by General Mills Co.) 75 gramsBetty Crocker brownie mix (manufactured by General Mills Co.) and 1365ml of tap water. Synthetic BM was then added to the back crotch area ofeach product through the plastic tube using a 60 cc syringe, having a 30mm inside cylindrical diameter and an outlet tip diameter of 4 mm andattached to the tube. The synthetic BM was pumped into the product untilleakage was visually detected at the leg openings of the product. Areading in cubic cm of total synthetic BM pumped in was taken at pointof failure, i.e. just as synthetic BM began to leak out of product. Theresults are shown in Table III below.

TABLE III BM Capacity, cm³ A 425 B 165 C 143 D 180 E 120 F  68 G 160 H 80

While this invention has been described as having a preferredembodiment, it will be understood that it is capable of furthermodifications. This application is thereby intended to cover anyvariations, equivalents, uses, or adaptations of the invention followingthe general principles thereof, and including such departures from thepresent disclosure as come within known or customary practice in the artto which this invention pertains and fall within the limits of theappended claims.

1. A disposable waste containment article, comprising: a wastecontainment structure comprising a backsheet, a substantially liquidpermeable bodyside liner, an absorbent core sandwiched between thebacksheet and the liner, and a pair of containment flaps joined to theliner; wherein the waste containment structure defines an open volumewell formed between the absorbent core and the containment flaps forreceiving directly and holding solid body exudates; and wherein theabsorbent core comprises 0 to 5 weight percent high absorbency materialand has an absorbent capacity of at least about 100 grams of syntheticurine, the absorbent core having a thickness in a dry state of less thanabout 1.25 cm. and a thickness in a wet state of less than about 0.8 cm.2. The article of claim 1, wherein a ratio of the thickness in a wetstate to the thickness in a dry state is 1.3 or less.
 3. The article ofclaim 2, wherein the ratio of the thickness in a wet state to thethickness in a dry state is about 1.05.
 4. The article of claim 1wherein said containment flaps are liquid pervious.
 5. The article ofclaim 1 wherein said containment flaps are substantially liquid porous.6. The article of claim 1 wherein said volume well holds at least about250 cm³ of solid exudates in the wet state.
 7. The article of claim 6wherein said volume well holds at least about 300 cm³ of solid exudatesin the wet state.
 8. The article of claim 7 wherein said volume wellholds at least about 400 cm³ of solid exudates in the wet state.
 9. Adisposable waste containment article, comprising: a waste containmentstructure comprising a backsheet, a substantially liquid permeablebodyside liner, an absorbent core sandwiched between the backsheet andthe liner, and a pair of containment flaps joined to the liner; whereinthe waste containment structure defines an open volume well formedbetween the absorbent core and the containment flaps for receivingdirectly and holding solid body exudates, the volume well holding atleast about 250 cm³ of solid exudates in a wet state; and wherein theabsorbent core has an absorbent capacity of at least about 100 grams ofsynthetic urine, a thickness in a dry state of less than about 1.25 cm.and a thickness in a wet state of less than about 0.8 cm.
 10. Thearticle of claim 9, wherein a ratio of the thickness in a wet state tothe thickness in a dry state is 1.3 or less.
 11. The article of claim10, wherein the ratio of the thickness in a wet state to the thicknessin a dry state is about 1.05.
 12. The article of claim 10, wherein theabsorbent core comprises 0 to 5 weight percent high absorbency material.13. The article of claim 9 wherein said containment flaps are liquidpervious.
 14. The article of claim 9 wherein said containment flaps aresubstantially liquid porous.
 15. The article of claim 9 wherein saidvolume well holds at least about 300 cm³ of solid exudates in the wetstate.
 16. The article of claim 15 wherein said volume well holds atleast about 400 cm³ of solid exudates in the wet state.
 17. A disposablewaste containment article, comprising: a waste containment structurecomprising a backsheet, a substantially liquid permeable bodyside liner,an absorbent core sandwiched between the backsheet and the liner, and apair of containment flaps joined to the liner; wherein the wastecontainment structure defines an open volume well formed between theabsorbent core and the containment flaps for receiving directly andholding solid body exudates; wherein the absorbent core has an absorbentcapacity of at least about 100 grams of synthetic urine, a thickness ina dry state of less than about 1.25 cm. and a thickness in a wet stateof less than about 0.8 cm.; and wherein a ratio of the thickness in awet state to the thickness in a dry state is 1.3 or less.
 18. Thearticle of claim 17, wherein the ratio of the thickness in a wet stateto the thickness in a dry state is about 1.05.
 19. The article of claim17 wherein said containment flaps are liquid pervious.
 20. The articleof claim 17 wherein said containment flaps are substantially liquidporous.
 21. The article of claim 17 wherein said volume well holds atleast about 250 cm³ of solid exudates in the wet state.
 22. The articleof claim 21 wherein said volume well holds at least about 300 cm³ ofsolid exudates in the wet state.
 23. The article of claim 22 whereinsaid volume well holds at least about 400 cm³ of solid exudates in thewet state.
 24. The article of claim 17 wherein the absorbent corecomprises 0 to 5 weight percent high absorbency material.